Ford transit 1978 1986 diesel engine hướng dẫn sửa chữa động cơ diesel trên ford transit đời 1978 1986

HƯỚNG DẪN SỬA CHỮA ĐỘNG CƠ DIESEL TRÊN XE FORD TRANSIT ĐỜI 1978-1986

ENGINE

General Description ` vẻ 2 Service Adjustments and Checks ia 7 Special Service Tool Recognition 8 Service and Repair Operations —

GENERAL DESCRIPTION

Transit range vehicles may have both diesel engines and various petrol engine types fitted Petrol engines are

in-line as well as V4 and V6 versions

This section covers the Ford diesel engine only For easier identification this engine is designated with the code letter ‘G’ in line with other workshop manuals The table below lists the engine types built in Germany

and the United Kingdom respectively

OHV = overhead valves

|-4 = in-line 4 cylinder engine

The ˆG' engine is a water-cooled 4 cylinder 4 stroke in-line indirect injection diese! engine (Fig 1)

The combined fuel injection and fuel lift pump, fuel filter, brake pump and full-flow oil filter are all located on the right-hand side of the engine The rotor o pump is located at the front and is driven by a crankshaft gear The fuel injection pump is driven via a toothed belt which also drives the camshaft Similarly, alternator, brake pump and water pump are driven by the crankshaft via a V-belt

In order to achieve low overall height (compact layout) the cylinders are mounted at an angle of 22,5 degrees

to the left of vertical To give maximum crankshaft drive stability the crankshaft is carried on five main bearings Centre main bearing end float is determined by four half thrust washers

The floating piston pins are located in the connecting rods (with bushes) and secured with two circlips Pistons have two compression rings and one oil scraper ring The camshaft which is carried on five bearings

is located in the cylinder block on one side of the engine and driven by the crankshaft via a toothed belt which, as already mentioned, also drives the fuel injection pump A drilling through the shaft carries oil to the replaceable bearings

Overhead valve timing is effected via tappets, push rods and rocker arms The rocker shaft has a drilling for rocker arm lubrication Valves are arranged in the cylinder head in alternating sequence, commencing with

an exhaust valve at the front of the engine Inlet valves have one progressive coil spring and exhaust valves two Valve adjusting screws are self-locking Inlet and exhaust valves have different seat angles Cylinder head valve guides are exchangeable

The thermostart control incorporated in the inlet manifold ensures quick starting of the engine in low

temperature conditions

An automatic shut-off control fitted to the engine compartment splash shield enables the injection pump to

be set to zero lift via a cable, thereby stopping the engine

The fuel injection pump timing mark is located on the advance unit on top of the pump

The engine has combustion chambers divided into a turbulence chamber located in the cylinder head and the main combustion chamber in the cylinder itself

GENERAL DESCRIPTION (cont'd)

Lubrication Circuit, Fig 2

The rotor oil pump located at the front of the engine block is driven by a gear on the crankshaft and draws oil via a strainer and suction pipe (lower drilling) from the oil sump

The filtered oil is fed through the upper drilling via the pump relief valve into the full-flow oil filter and from there through the central axis of the oil filter cartridge to the main oil gallery A by-pass valve located on the filter central axis opens in order to enable oil to pass directly into the main gallery in the event of oil filter cartridge blockage (by sludge, etc.)

The pump relief valve in the cylinder block, between the oil pump and the full-flow oil filter, is connected to

the main oil gallery Excessive oil pressure will force a small spring-loaded plunger downwards, with the downward movement of the plunger freeing the valve plunger drillings in the direction of the lower gallery thereby providing a direct connection between oil suction tube and pressure duct

The five main bearings are connected to the main oil gallery The big end journals are supplied with oil via diagonal lubrication passages from the nearest main crankshaft bearing

The first four main bearing supports in the cylinder block have splash oil drillings which ensure splash jubrication of piston pins and better cooling of piston tops

From the centre main bearing the oil passes via the centre camshaft bearing to the camshaft and from there through drillings to the remaining camshaft bearings

Oil flows from the centre camshaft bearing through a cylinder block drilling to the cylinder head into the rocker arm shaft and to the rocker arms Valve stems are lubricated by means of oil discharged through the rocker arm drilling

Both the fuel injection pump and the lift pump are permanently lubricated with oil from the main oil gallery fed to the pumps via engine block and timing cover drillings The return oil flow to the pump passes through the timing cover The oil pressure switch which is screwed into the gallery on the right-hand side of the engine block is in direct communication with the main oil gallery

Fig 2 Lubrication circuit

1 Valve stem drip feed lubrication system 5 Rotor oil pump

2 Fuet injection pump 6 Oil pump relief valve

3 Exhauster pump 7 Qit suction strainer

4 Full-flow oil filter 8 Piston splash lubrication system

GENERAL DESCRIPTION (cont'd)

Engine Ventilation System, Fig 3

The mixture of air and crankcase fumes passes through the cylinder head into the rocker cover from where

it is drawn through the oil separator and oil filler connecting hose into the inlet manifold and the filtered air,

together with the air drawn through the air cleaner, is fed into the cylinder combustion chambers

GENERAL DESCRIPTION (cont'd)

Engine Identification and Serial

Numbers

Regulations in force in certain countries provide for

engines to be marked with identification codes and

serial numbers Fig 4 and 5 show where these data

are marked on the engine Minimum height of

letters and numbers is 6 mm (0,25 in) and both

codes and serial numbers (e.g on replacement

engines) should be marked in such a manner that

they can be clearly recognised by the appropriate

testing authorities, thereby preventing rejection of

engines

SERVICE ADJUSTMENT AND CHECKS

To check the engine oil level the vehicle should

stand on level ground and the engine should be at

normal operating temperature Before carrying out

the check, wait a short time to allow all oil to

drain back into the sump

Withdraw the dipstick, wipe it clean with a non-

fluffy rag, replace and withdraw it again The oil on

the dipstick indicates the oil level in the sump,

which should lie between the two marks, Fig 6

The quantity of oil required to top up from the

bottom mark to the top mark is approximately

1,7 litre (3,0 pints)

If necessary, top up through the filler neck, with

engine oil to FORD specification

Topping up is not necessary until the oil level drops

to the bottom mark Do not allow the oil level to

drop any further Never top up to above the top

mark since the excess oil is wasted, i.e the oil

consumption is increased

The engine oil should be changed and the full-

flow oil filter renewed at 5000 km (3000 mile)

intervals If conditions of use are severe, e.g short

trips, frequent starts from cold, dusty roads, etc., the

oil should be changed and the oil filter renewed at

shorter intervals

If the specified engine oil is not used the inevitable

consequence will be excessive wear or damage to

the engine The oil film becomes discontinuous and

engine components under high thermal stresses are

subjected to increased wear Residues collect in the

sump and block oil passages In addition, poor

quality oil does not protect against corrosion so

that rust forms on the cylinder walls After a

relatively short time the efficiency of the engine

will decrease and there will be increased fuel and

oil consumption Always use a branded oil comply-

ing with FORD specifications

Camshaft bearing shell

SPECIAL SERVICE TOOL RECOGNITION (cont'd)

British European German

Sourced Sourced Sourced S2 SE

Engine lifting eye — rear

SERVICE AND REPAIR OPERATIONS —- CONTENT

publication | Operation TRANSIT

21 132 Engine and transmission assembly — remove and

21 134 8 Engine — dismantle and reassemble (engine

21 146 Cover-timing belt — remove and install — 21 288 x

21 217 4 Valves — remove and install (cylinder head

21 255 9 Rocker shaft assembly — overhaul (rocker shaft

21 286 6 Bearings — camshaft — replace (engine dismantled) x x

21 468 4 Seal — crankshaft rear — replace (engine or

21 505 5 Piston — replace (piston and connecting rod

21 584 5 Ring gear — flywheel — replace (flywheel removed) x X

SERVICE AND REPAIR OPERATIONS

COMPRESSIONS

Service Tools and Testing Equipment

Injection pipe nut wrench 21-041

Standard compression testing equipment

The majority of test instruments are of dif-

ferent design and usually enable compression

to be checked on one cylinder only Determin-

ation of the actual compression pressure is

dependent on several factors, 9.g varying

starter motor speeds, or state of charge of the

battery It is, however, essential for at least

two requirements to be met, namely, that the

engine temperature is normal and valve clear-

ances are adjusted as specified in Technical

Data

To Check

1 Remove inlet manifold

2 Disconnect cable from shut-off unit to inter-

rupt fuel supply

3 Unscrew fuel injector pipes using Special

Tool 21-041, Fig 7 and disconnect overflow

pipe from nozzle brackets

4 Remove injectors and withdraw nozzle bracket

sealing ring and heat balancing plate

5 Screw compression pressure tester with new

graph paper to injector nozzle orifice con-

cerned, Fig 8 and crank engine until pointer

of tester rises no further (compression

pressure data see Technical Data)

6 Vent tester, adjust graph paper for next cylin-

der and repeat sub-op 5 for all other cylin-

ders

7 Fit new sealing ring and new heat balancing

plate with domed side facing upwards, Fig 9

and tighten injector nozzles as specified in

Technical Data

8 Fit injector pipes as specified, using Special

Tool 21-041 and install overflow pipe

9 Connect cable to shut-off motor and fit air

Fig 9 Turbulence combustion chamber

A — Turbulence combustion chamber element

B — Engine heat shield

C — Engine heat shield gasket

D — Nozzle bracket sealing ring

E — Heat balancing plate

21 112 oILPRESSURE CHECK

Testing equipment required:

Oil pressure test gauge

Oil pressure depends on various factors

(engine speed, oil temperature, oil pump rotor

clearance, etc.) Pressure should always be

checked at an temperature of 355°K (80

°C) (176°F) At idling speed oil pressure

should be 1,0 bar (kgf/cm?) (14,2 Ibf/in?)

Maximum pressure should however, not

exceed 5 bar (kgf/cm?) (71 Ibf/in?) at speeds

above 2000 rpm

If pressures are outside these limits first eliminate

oil pump, Fig 10 or relief valve, Figs 11 and 12, as

possible sources of fault The following faults can

occur, e.g.:

Pressure too high at speeds over 2000 rev/min;

Failure of relief valve to open because of fouling

Pressure too low at all engine speeds: Clogged

intake strainer, intake pipe loose or broken, oil

pump worn, etc

Pressure too low at low engine speeds: Relief valve

jammed in open position due to dirt

To measure oil pressure

1 Remove oil pressure switch connecting lead

and remove oil pressure switch

2 Connect test pressure gauge to engine block,

using adaptors, if necessary

3 Start engine and check oil pressure at idling

speed and at over 2000 rev/min

4 Remove test pressure gauge Replace oil pres-

sure switch and connect lead as specified in

21 132 ENGINE AND TRANSMISSION

ASSEMBLY — REMOVE AND

INSTALL

Special Service Tools Required:

Engine liftingeyes G1-8000

Engine lifting tackle G2-8000

Engine lifting eye —front - 21-026

Engine lifting eye — rear ei 21-027

To Remove

in Disconnect both battery earth cables, as well

as positive lead from left-hand battery

Disconnect washer assembly hoses from

nozzles and retaining clamps and remove

hood (4 bolts)

Drain coolant into tray, disconnecting lower

radiator hose from water neck, Fig 13, and

upper hose from thermostat water neck and

remove

Remove coolant expansion tank connecting

pipe (2 bolt), Fig 14 and remove expansion

tank complete with bracket from engine (3

bolts)

Disconnect radiator (2 bolts) bottom mounting

from crossmember mountings, Fig 15

6 Unhook hood cable at catch end (Fig 16) and

disconnect from radiator grille panel

Fig 16 Unhook hood cable

7 Remove right-hand and left-hand headlamp

surround (1 bolt each)

8 Remove radiator grille panel complete with

radiator and expansion tank, as well as con-

necting pipe, Fig 17

Fig 17 Remove radiator grille panel complete with radiator, expansion tank and connecting pipe

9 Remove air cleaner (2 bolts)

10 Disconnect cables from shut-off motor and in-

jection pump, Fig 18

21 132 (cont'd)

11, Disconnect fuel feed and return line from

pump and remove fuel filter and thermostart

reservoir lines from intake manifold

12 Disconnect temperature sender unit, oil press-

ure switch, glow plugs, starter motor and

alternator Remove positive left-hand battery

cable from body

13 Disconnect brake servo vacuum hose from

pipe and remove, Fig 19

Fig 19 Remove brake servo vacuum hose

14, Remove water drain neck and heater hoses

from splash panel, Fig 20

Fig 20 Remove heater hoses

15 Disconnect exhaust pipe from manifold

(2 bolts)

16 Remove transmission gearshift lever mount-

ing bracket (6 bolts) and raise gaiter Remove

gear shift lever cap nut, Fig 21 and with-

draw gearshift lever

17 Remove clutch cable from pedal bracket, Fig

22,

Fig 22 Remove clutch cable from pedal bracket

18 Disconnect left-hand and right-hand earth

cables from clutch housing and remove speed-

ometer drive cable from transmission (1 bolt),

BigziZ3:

Fig 23 Remove speedometer drive cable

19 Pull back gaiter and unhook clutch cable from

release lever, Fig 24

Disconnect drive shaft at rear axle flange

(4 bolts), Fig 25 and floor pan centre bearing

(2 bolts), withdraw drive shaft from gearbox

extension housing and fit blanking plug

Attach engine lifting eyes 21-026/27 to

engine, Fig 26 and fit engine lifting appliance

G2-6000 with engine lifting eye G1—6000

Hook engine lifting appliance into standard

workshop lifting jack and gently take up

engine weight

Remove transmission from rear engine mount-

ing (1 bolt), Fig 27 and engine from mount-

ing rubber insulator (2 nuts)

Carefully raise engine complete with trans-

mission and lift out of engine compartment

Carefully position engine complete with gear-

box in engine compartment and fit on front

and rear engine mounting Tighten as specified

in Technical data

Remove engine lifting appliance

Withdraw blanking plug from gearbox exten-

sion housing, carefully insert driveshaft and

attach to rear axle flange and centre bearing

as specified in Technical data, Fig 28

Connect speedometer drive cable Hook clutch

cable into release lever and install gaiter Fit

earth cable left and right to clutch housing

and attach left-hand battery positive lead to

body

Adjust clutch cable clearance at pedal bracket,

Fig 29

Install gearshift lever and tighten nut Locate

gaiter and fit mounting bracket

Bolt exhaust pipe to manifold

Fit heater hoses and water drain neck, Fig 30

Connect leads to temperature sender unit, oil

pressure switch, glow plugs, starter motor and

alternator

Connect fuel filter and thermostart reservoir

pipes to inlet manifold and fit fuel feed and

return lines to pump

Fit fuel injection pump and shut-off motor

cables, then bleed the fuel system — refer to

38 Insert radiator grille panel complete with

radiator and expansion tank and secure, Fig

34 Fit both headlamp surrounds

Fig 34 Install radiator grille panel complete with radiator connecting pipe and expansion tank

39 Hook hood cable into catch, Fig 35 and fit

to radiator grille panel

Fig 35 Fit hood cable

40 Replace radiator at bottom location to cross-

member mountings, Fig 36

21 1 32 (cont'd)

41 Fit expansion tank with bracket to engine,

Fig 37 and attach expansion tank connecting

pipe

Fig 37 Fit expansion tank

42 Replace lower and upper radiator hoses and

secure, Eig, 3c

Fig 38 Fit upper radiator hoses and secure

43 Top up coolant and engine oil Check trans-

mission oil level and top up, if required

44 Position hood, hand-tighten bolts, align hood

and secure Position washer system hoses,

Fig 39 and slide on to nozzles

45 Connect earth cables to both batteries and

positive lead to left-hand battery

21 134 8 ENGINE -DISMANTLE AND

REASSEMBLE (ENGINE REMOVED)

Special Service Tools Required:

Crankshaft rear oil seal installer 21-011-A

Engine mounting bracket 21-015

Camshaft gear alignment pin 21-016

Camshaft oil seal installer e017)

Crankshaft flange holding wrench 21-018

Crankshaft bolt remover/replacer_ 21-019

Universal shaft 21-023

Crankshaft front oil seal centraliser 21-025

Crankshaft spigot bearing extractor 21-036

Injector pipe nut wrench 21-041

Clutch disc centraliser 5 21-044

Crankshaft spigot bearing installer 21-045

Engine stands 21-061-A/B8/C/D

To Dismantie

1ˆ

Bì

Remove front left-hand engine mounting

rubber insulator, then fit engine stand(s)

21—061—A/B/C/D using mounting bracket

21-015 and universal shaft 21-023, Fig 41

Drain engine oil, withdraw oil dipstick and

unscrew full-flow oil filter cartridge Remove

oil filler cap with breather hose

Using special tool 21-041 remove overflow

pipe from nozzles, injection pump and injector

lines, Fig 42

Fit caps to nozzle and pump line connect-

ors for protection from contamination

Remove injection pump filter fuel lines and

engine vacuum pump air line

Remove fuel filter complete with bracket

6 Slacken vacuum pump V-belt tension roller

Fig 44 and alternator V-belt adjuster, then

remove both V-belts

7 Remove alternator complete with bracket (4

bolts)

Remove fan with pulley (4 bolts)

9 Remove crankshaft pulley (6 bolts)

10 remove upper and lower toothed belt cover

bolts and remove cover, Fig 45

11 Remove rocker cover (6 bolts)

12 Remove three lower then five upper rocker

support bracket bolts Remove rocker shaft and

withdraw push rods

Do not interchange push rods when re-

moving and installing

13 Remove injector nozzles (2 bolts each), then

lift out nozzle holder sealing rings and heat

balancing plate Withdraw heat shields and

gaskets, using 2 screwdrivers

14, Remove water neck (2 bolts) and lift out

thermostat, noting location, Fig 46

21 134 8 (cont'd)

15 Slacken water pump to cylinder head by-pass

hose, Fig 47

16 Remove cylinder head bolts (18), unscrewing

them in reverse order from that in which they

were tightened (for tightening sequence see Fig 90) Lift off cylinder head complete with inlet and exhaust manifolds

Do not place cylinder head on gasket face

17 Remove clutch pressure plate (6 bolts) fly-

wheel (8 bolts), and engine backplate (2 bolts)

Fig 47 Slacken by-pass hose

18 Remove sump (24 bolts) downwards to

prevent sludge or swarf getting into engine

19 Slacken toothed belt tensioner and remove

toothed belt, Fig 48, then remove tensioner (2 bolts)

Fig 48 Remove toothed belt

20, Remove crankshaft hub bolt, using Special

Tool 21-018/019, Fig 49 Remove crank- shaft hub using standard extractor

21 Lock camshaft toothed belt gear with Special

Too! 21-016, Fig 50 Unscrew bolt and press

off gear using two levers

22 Remove water pump with by-pass hose from

intermediate plate (7 bolts), Fig 51

23 Remove vacuum pump pulley, Fig 52, using

standard extractor if necessary

21 134 8 (cont'd)

24 Remove front cover from intermediate plate

(10 bolts)

25 Remove oil pump with mounting (3 bolts)

from engine block, Fig 53

Fig 53 Remove oil pump

26 Remove vacuum pump bracket and pump from

intermediate plate (3 bolts) Fig 54

Fig 54 Remove vacuum pump

27 Remove injection pump bracket from engine

block (2 bolts), then remove intermediate

plate complete with injection pump (10 bolts),

28 Remove camshaft and crankshaft spacer, as well as crankshaft gear, by hand

29 Withdraw crankshaft spigot bearing, using Special Tool 21-036, Fig 56

TR21-08, Fig 56 Remove crankshaft needle bearing using Special Tool 21-036

30 Remove crankshaft rear oil seal carrier (4 bolts), Fig 57

31 Remove camshaft rear cover plate bolts (3) and camshaft thrust plate bolts (2), Fig 58

Remove plates and carefully withdraw camshaft

TR2t-oa Fig 57 Remove crankshaft oil seal carrier

32, Remove tappets from engine block

Do not interchange tappets when re- moving and installing

33 Remove oil pump suction pipe (2 bolts)

34 Remove big end bearing caps (2 nuts each)

and bearing shells

Note connecting rod, bearing cap and

bearing markings

Fig 59 Big end journal markings

35 Carefully scrape off carbon deposits from

cylinder bore top ends, then withdraw piston

and connecting rod assemblies upwards from

the block Remove piston rings, clean grooves

and fit new rings into grooves, with ‘TOP’

mark pointing upwards, Fig 60

Fig 60 Fit piston rings

A — Upper piston ring

B ~ Lower stepped ring

C ~ Oil scraper ring

36 Remove main bearing caps (2 bolts each) and

shells Note centre main bearing thrust

washers

Note bearing shell and cap markings, Fig

61

37 Carefully lift crankshaft out of engine block

38 Remove oil pressure switch and pressure relief

To Reassemble

The type and degree of cleaning of a given

part before reassembly must depend on the

hours the engine has run, the extent of any

damage and its possible re-use This applies

particularly to the cylinder block ith its

corners, angles and bores If necessary, re-

move all plugs and covers and clean their

seats, using suitable cleaning agents and

tools (brushes, scrapers) The oil galleries in

particular, e.g in the cylinder block, cylinder

head, etc., should be free from dirt and

abrasive particles, Fig 62 If press-fit plugs

and screw plugs are removed, they, like all

seals and gaskets, should be renewed

Measuring Bearing Clearance

Measuring bearings (even with undersize crank-

shafts) can be eliminated and determination of re-

quired bearing shells can be considerably simplified

by use of:

ˆPLASTIGAGE' made by:

PERFECT CIRCLE CORPORATION,

HAGERSTOWN, INDIANA, USA

“PLASTIGAGE' is the name of an accurately cali-

brated plastic filament

Type Colour Measuring range

PG-1 green 0,025-0,075 mm (0,001-0,003 in)

PR-1 red 0,050-0,150 mm (0,002-0,006 in)

PB-1 blue 0,100-0,230 mm (0,004-0,01 in)

Requirements for use of ‘Plastigage’

1 Bearing should be dry and clean

2 Crankshaft should be

measuring operation

not turned during

3 Points of measurement should be close to

top dead centre position

4 Bearing caps should not be seated with

hammer blows

Place length of Plastigage across width of bearing

on crankshaft or big end journal Fit main or big

end bearing cap together with bearing shells and

torque as specified The plastic filament will be

compressed more or less depending on bearing

clearance Remove bearing cap

Each main bearing should be measured

separately without other bearing caps being

Fig 62 Oil circuit

Width of compressed plastic filament can be measured by means of scale printed on PLASTI-

GAGE pack, Fig 63; reading shows bearing: clear-

ance

Only bolts in good condition should be used for securing bearing caps on crankshaft and they should not be tightened in excess of

Fig 63 Measuring bearing play

A — Compressed plastic thread

B — Measurement scale

December 1976 TRANSIT: SECTION 21B-31

When re-assembling an engine, the piston to

bore clearance should be measured as follows

The diameter of the piston should be measured

when cold, using a micrometer The measure-

ment should be made across the piston skirt,

at 90° to the piston axis

This micrometer reading is then used to ‘zero’

a bore gauge The reading on the dial of the

bore gauge in situ is the piston to bore

clearance (See Technical Data.)

Alternatively, the bore can be measured with

an internal micrometer, and the piston size

subtracted to give the piston to bore clearance

The measurement must be taken below any

visible wear marks in the bore To detect bore

ovality, two readings should be taken at 90°

to each other

NOTE: The maximum difference between

se two readings should not be more than

5 mm (0,001 in)

Inspect the bores for visible wear, damaged

lips, etc

If the clearance in sub-section (c) above is

excessive, or if ovality, or any of the faults in

sub-section (e) above is detected, the block

should be rebored to suit oversize pistons

Before installing pistons, check piston ring

gaps (Fig 64)

Fit oil pressure switch Lubricate oil pressure

valve tappets and fit valve assembly, Fig 65

Insert main bearing shells dry into engine

block, on centre bearing locate both thrust

washers in cylinder block re es in such a

manner that oilways are visible (Fig 66)

Lubricate bearing shells and carefully insert

crankshaft

41

42

ta)

(b)

Refit main bearing cap complete with

lubricated bearing shells, again paying

attention to correct location of thrust

half washers on centre main bearing cap,

Fig 67 Tighten bearing cap bolts as

specified in Technical Data

Fit centre main bearing cap bolts finger-

tight only Press crankshaft first to rear

against stop, then slowly and firmly

against front stop and hold in position

and torque bolts, Fig 68 (This operation

is necessary to ensure uniform seating

of thrust washers.)

Main bearing caps should be fitted

with arrow pointed forward

Check crankshaft end float using standard

dial indicator, Fig 69 Use oversize thrust

21 134 8 (cont'd)

43 Apply engine oil to pistons and cylinder bores

Stagger piston rings with maximum spacing

Compress piston rings with standard ring

compressor and press pistons into cylinders

using hammer handle, Fig 70, guiding con-

necting rods with oiled bearing shells on to

big end journals by hand

Front marking on pistons and connecting

rods should point forward

44 Fit big end bearing caps complete with oiled

bearing shells and torque new self-locking

bolts as specified in Technical Data

Marks on connecting rods and bearing

caps should be on one side

Fig 70 Fit piston using standard ring compressor

45 Oil valve tappets and fit into same bores as on

removal Oil and carefully insert camshaft, pay-

ing attention to correct location of camshaft

oil gallery sealing balls Fit cover plate and

thrust plate

Fig 71 Press in crankshaft rear oil seal using Special Tool 21-011-A

46 Replace crankshaft rear oil seal:

Drive oil seal from oil seal carrier using

hammer and mandrel, slightly oil sealing lip of

new oil seal and carefully drive into oil seal

carrier, using Special Tool 21-011-A, Fig 71

Then fit oil seal carrier and new oil seal,

centralise with same Special Tool and secure,

Rig: 7.2

Check correct location of oil seal carrier

on sump sealing surface

47 Fit oil pump suction pipe with new gasket

48 Fit crankshaft needle bearing using Special

Tool 21—045, Fig 73

49 Fit crankshaft gear

50 Replace camshaft oil seal:

Drive oil seal from intermediate plate using

hammer and mandrel, slightly oil sealing lip

of new oil seal and carefully draw into inter-

mediate plate using Special Tool 21-017 with

bolt and washer, Fig 74 Then fit intermediate

plate with new gasket complete with injection

pump (also with new O-rings), centralise with

same Special Tool, fit bolts in correct

sequence as specified in Technical Data, Fig

5s

Check correct location of intermediate

plate on oil sump sealing face

21 134 8 (cont'd)

51 Fit injection pump bracket to engine block

52 Fit vacuum pump with bracket to intermediate

plate

Fig 76 Fit oil pump O-rings

53 Fit oil pump with new O-rings, Fig 76 and

secure, Fig 77

Before installing oil pump rotate by hand

and fill with engine oil

Oil pump bores are offset and pump can

therefore be installed in one position only

TR2IJTS=<>—_— ^

Fig 77 Fit oil pump

54 Check oil pump gear backlash, Fig 78, (see

Technical Data) and fit new gears, if required

55 Replace crankshaft front oil seal:

Drive oil seal out of timing cover using

hammer and mandrel Slightly oil sealing lip of

new oil seal, carefully drive into timing cover,

using Special Tool 21-025, Fig 79, then fit

timing cover and new gasket to intermediate

plate Centralise with same Special Tool, Fig

80 and secure, fitting bolts coated with sealing

Fig 80 Centralise timing cover using Special Tool 21-025

57 Fit water pump with new gasket to inter-

mediate plate, Fig 81